WIRING DIAGRAMS
CONTRACTOR _______________________ PURCHASER ____________________________________________ ORDER NO. _________________________ JOB NAME ______________________________________________ YORK CONTRACT NO. _________________ LOCATION _____________________________________________ YORK ORDER NO. ____________________ ENGINEER ______________________________________________
REFERENCE DATE ________ APPROVAL DATE ________ CONSTRUCTION DATE ________
Supersedes: 160.77-PW2 (311) Form: 160.77-PW2 (911)
UNIT WIRING AND FIELD CONTROL MODIFICATIONS
MODEL YKEP CHILLER
JOB DATA:
CHILLER MODEL NO. YKEP
NO. OF UNITS
Issue Date: September 23, 2011
JOHNSON CONTROLS2
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
This equipment is a relatively complicated apparatus. During installation, operation maintenance or service, individuals may be exposed to certain components or conditions including, but not limited to: refrigerants, materials under pressure, rotating components, and both high and low voltage. Each of these items has the potential, if misused or handled improperly, to cause bodily injury or death. It is the obligation and respon-sibility of operating/service personnel to identify and recognize these inherent hazards, protect themselves, and proceed safely in completing their tasks. Failure to comply with any of these requirements could result in serious damage to the equipment and the property in
IMPORTANT!READ BEFORE PROCEEDING!
GENERAL SAFETY GUIDELINES
which it is situated, as well as severe personal injury or death to themselves and people at the site.
This document is intended for use by owner-authorized operating/service personnel. It is expected that these individual possess independent training that will en-able them to perform their assigned tasks properly and safely. It is essential that, prior to performing any task on this equipment, this individual shall have read and understood this document and any referenced mate-rials. This individual shall also be familiar with and comply with all applicable governmental standards and regulations pertaining to the task in question.
SAFETY SYMBOLSThe following symbols are used in this document to alert the reader to specific situations:
Indicates a possible hazardous situation which will result in death or serious injury if proper care is not taken.
Indicates a potentially hazardous situation which will result in possible injuries or damage to equipment if proper care is not taken.
Identifies a hazard which could lead to damage to the machine, damage to other equipment and/or environmental pollution if proper care is not taken or instructions and are not followed.
Highlights additional information useful to the technician in completing the work being performed properly.
External wiring, unless specified as an optional connection in the manufacturer’s product line, is not to be connected inside the cabinet. Devices such as relays, switches, transduc‑ers and controls and any external wiring must not be installed inside the micro panel. All wiring must be in accordance with Johnson Controls’ published specifications and must be performed only by a qualified electrician. Johnson Controls will NOT be responsible for damage/problems resulting from improper connections to the controls or application of im‑proper control signals. Failure to follow this warning will void the manufacturer’s warranty and cause serious damage to property or personal injury.
JOHNSON CONTROLS 3
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
CHANGEABILITY OF THIS DOCUMENT
In complying with Johnson Controls’ policy for con-tinuous product improvement, the information con-tained in this document is subject to change without notice. Johnson Controls makes no commitment to update or provide current information automatically to the manual owner. Updated manuals, if applicable, can be obtained by contacting the nearest Johnson Controls Service office.
Operating/service personnel maintain responsibility for the applicability of these documents to the equipment. If there is any question regarding the applicability of these documents, the technician should verify whether the equipment has been modified and if current litera-ture is available from the owner of the equipment prior to performing any work on the chiller.
ASSOCIATED LITERATUREMANUAL DESCRIPTION FORM NUMBER
YKEP Installation and Re-Assembly 160.77-N1
YKEP Unit Operation and Maintenance 160.77-O1
YKEP Unit and Control Panel Renewal Parts 160.77-RP1
YKEP Installation Checklist 160.77-CL1
YKEP Startup Checklist 160.77-CL2
YKEP Wiring Diagram - Field Connections 160.77-PW1
YKEP Wiring Diagram - Unit Wiring 160.77-PW3
Liquid Cooled Solid State Starter - Operation 160.00-O2
Medium Voltage Variable Speed Drive (2300v - 6600v) - Operation 160.00-O6
Medium Voltage Variable Speed Drive (10,000v - 13,800v) - Operation 160.00-O8
Unit Mounted Medium Voltage Solid State Starter (2300v - 4160v) - Operation 160.00-07
Liquid Cooled Solid State Starter - Operation 160.00-O2
Long-Term Storage Requirements - General 50.20-NM1
Long-Term Storage Requirements - Field Preparation 50.20-NM5
Long-Term Storage - Periodic Checklist and Logs 50.20-CL5
JOHNSON CONTROLS4
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
NOMENCLATURE
LD15116
JOHNSON CONTROLS 5
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
TABLE OF CONTENTS
SECTION 1 - UNIT WIRING ......................................................................................................................................7
SECTION 2 - FIELD CONTROL MODIFICATIONS ................................................................................................39
SECTION 3 - ENERGY MANAGEMENT SYSTEMS ..............................................................................................47
JOHNSON CONTROLS6
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
LIST OF FIGURES
FIGURE 1 - Unit Device Locations Pressure Transducers ........................................................................................8FIGURE 2 - Unit Device Locations Temperature Sensors .........................................................................................9FIGURE 3 - Control Panel Layout ...........................................................................................................................10FIGURE 4 - Stall Detector Board Details................................................................................................................. 11FIGURE 5 - Compact I/O 1769-IAI6 Digital Input Slot 1 ..........................................................................................12FIGURE 6 - Compact I/O 1769-OW81 Digital Output Slot 2 ...................................................................................13FIGURE 7 - Compact I/O 1769-OA8 Digital Output Slot 3 ......................................................................................14FIGURE 8 - Compact I/O 1769-OW81 Digital Output Slot 4 ...................................................................................15FIGURE 9 - Compact I/O 1769-IF8 Analog Input Slot 5 ..........................................................................................16FIGURE 10 - Compact I/O 1769-IF8 Analog Input Slot 6 ........................................................................................17FIGURE 11 - Compact I/O 1769-IF8 Analog Input Slot 7 ........................................................................................18FIGURE 12 - Compact I/O 1769-IR6 RTD Input Slot 8 ...........................................................................................19FIGURE 13 - Compact I/O 1769-IR6 RTD Input Slot 9 ...........................................................................................20FIGURE 14 - Compact I/O 1769-OF2 Analog Output Slot 10 .................................................................................21FIGURE 15 - Compact I/O 1769-OF4VI Analog Output Slot 11 ..............................................................................22FIGURE 16 - Oil Pump ............................................................................................................................................23FIGURE 17 - Subcooler / Oil Sump .........................................................................................................................24FIGURE 18 - Liquid Cooled Solid State Starter.......................................................................................................24FIGURE 19 - Actuator Wiring ..................................................................................................................................25FIGURE 20 - Connector Details ..............................................................................................................................25FIGURE 21 - Component Connection Details .........................................................................................................26FIGURE 22 - Elementary Diagram ..........................................................................................................................28FIGURE 23 - Compressor Actuators / Stall Detector Boards ..................................................................................29FIGURE 24 - Variable Speed Oil Pump Panel Wiring .............................................................................................30FIGURE 25 - Wiring Diagram ..................................................................................................................................32FIGURE 26 - 120VAC and Low Voltage Connection Diagram ................................................................................34FIGURE 27 - Connection Diagram ..........................................................................................................................36FIGURE 28 - Variable Speed Oil Pump Panel ........................................................................................................38FIGURE 29 - Remote Ready To Start Contacts ......................................................................................................40FIGURE 30 - Cycling Shutdown Contacts ...............................................................................................................40FIGURE 31 - Safety Shutdown Contacts ................................................................................................................40FIGURE 32 - Run Contacts .....................................................................................................................................40FIGURE 33 - Anticipatory/Alarm Contacts ..............................................................................................................41FIGURE 34 - Remote Start and Stop Contacts From Energy Management System Contacts ...............................41FIGURE 35 - Chilled Water Pump Starter ...............................................................................................................41FIGURE 36 - Condenser Motor Pump Starter .........................................................................................................42FIGURE 37 - Condenser Flow Switches .................................................................................................................42FIGURE 38 - Evaporator Flow Sensors ..................................................................................................................43FIGURE 39 - Two Unit Sequence Control ...............................................................................................................44FIGURE 40 - Multiple Units (Two) - Series Operation .............................................................................................44FIGURE 41 - Multiple Units (Two) Parallel Operation - Individual Unit Pumps .......................................................45FIGURE 42 - Multiple Units (Two) Parallel Operation - Single Chilled Water Pump ...............................................45FIGURE 43 - Remote Hardwired Analog Temperature Setpoint .............................................................................45FIGURE 44 - Demand Limit Hardwired Remote......................................................................................................46
JOHNSON CONTROLS 7
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
1SECTION 1 - UNIT WIRING
1. All wiring shall be in accordance with the national electric code as well as all other applicable codes and specifications.
2. An underlined contact location signifies a nor-mally closed contact. Numbers within parenthesis (beneath contacts) indicate line number location of relay or timer coil.
3. Numbers adjacent to circuit lines are the circuit identification.
4. The primary compressor motor may be supplied with a UMMVSSS (Per R-1157), MVVSD (Per R-1150) or electomechanical (Per R-787) starter. Run interlock is only used on remote mounted electromechanical starter. All interface wiring for the remote mounted MVSSS, MVVSD and elec-tromechical starters is supplied and installed by others.
5. Ground control panel cabinet.
6. Identify all control panel wiring using heat shrink-able type wire markers.
7. For wiring other than pre-wired cables for PLC I/O modules. Use appropriate wire size depending on AMP rating of circuit breaker protecting the conductor: Derated for 50 degree C/122 degree F using YORK/Johnson Controls C-10 standard.
30 AMPS - #10 AWG20 AMPS - #12 AWG15 AMPS - #14 AWG10 AMPS - #16 AWG
All wire material must be per YORK/Johnson Controls C-10 standard. Unless otherwise noted all panel wiring to be 16 AWG. Unless otherwise noted wire color coding to be as follows:
115 VAC Hot - Black115 VAC Neutral - White+/- 5 VDC - Dark Blue+/- 24 VDC - Dark BlueGround - Green/Yellow3 Phase - Black
Field wiring must be sized by the installing con-tractor using appropriate derating factors for am-bient conditions and number of conductors in con-duit as required by 2008 NEC article 310.
8. Three phase oil pump must be properly phased. IL1, IL2 and IL3 corresponding to phase sequence A, B and C.
9. A coil transient suppressor must be installed on every coil or inductive load connected to the 129 VAC output module unless otherwise noted. Sup-pressors are supplied with control panel for field installation if needed.
10. Install 1 each flow sensor in each of the heat ex-changer's outlet nozzle. Use the 1/2" coupling best suited for sensor installation.
11. Secure conduits and cables together with cable straps.
12. Provide “Drip Loops” to 120 volt or greater wire harnesses to prevent water from entering junction boxes, panels, etc.
13. Assemble wires to existing harness in panel and solid state starter with Item 61.
14. Pack insulation into motor terminal box after con-nection of motor leads.
JOHNSON CONTROLS8
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
FIGURE 1 - UNIT DEVICE LOCATIONS PRESSURE TRANSDUCERS
CONTROL PANEL
Economizer Level Valve Actuator
Economizer Refrigerant Pressure Transducer
Subcooler Level Valve Actuator
Primary Compressor Pre-Rotation Vane Motor
Primary Compressor Liquid Injection Solenoid Valve
Primary Compressor Oil Return Solenoid Valve
Evaporator Pressure Transducer
Primary Compressor Oil Pump Pressure Transducer
Primary Compressor Stall Detector Pressure Transducer Condenser
Pressure Transducer
Economizer Compressor Thrust Switch
Economizer Compressor Pre-Rotation Vane Motor
Economizer Compressor VGD Position
Economizer Compressor Oil Pump Pressure Transducer
Economizer Compressor Stall Detector Pressure Transducer
LD15723
JOHNSON CONTROLS 9
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
CONTROL PANEL
Condenser Flow Sensor
Economizer Compressor PRV Closed Limit Switch
Economizer Compressor Variable Geometry Diffuser
Entering Condenser Water Sensor
Leaving Condenser Water Sensor
Evaporator Flow Sensor
Leaving Chilled Water Sensor
Economizer Level Sensor
Economizer Compressor Discharge Sensor
Evaporator Refrigerant Liquid Temperature Sensor
Subcooler Refrigerant Level Sensor
Primary Compressor Variable Geometry Diffuser
Primary Compressor Discharge Temperature Sensor
Leaving Chilled Water Sensor
Primary Compressor PRV Closed Limit Switch
FIGURE 2 - UNIT DEVICE LOCATIONS TEMPERATURE SENSORSLD15723a
JOHNSON CONTROLS10
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
FIGURE 3 - CONTROL PANEL LAYOUTLD14648
JOHNSON CONTROLS 11
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
PS
1 (c
omm
on)
TB2-
3
PS
2 (5
VD
C)
TB2-
1
TPF
GND -5V +5V
TPE TPD TPK TPL
J2 J2
TB1
HISTD
TPA
TPJ
SIG IN
OUT2
OUT1
3 1
1
1
TPMTPCTPB
TPG
TPH
031-02418-001REV
J1J1
To EconomizerStall Detector
Discharge Pressure(PE -149B)
3
2
1
J1
J2{J3
BLACK
WHITE
RED
1
2
4
3
+5 194
INPUT 209
213
GND 195
RED
BLACK
GREEN
WHITE
TPF
GND -5V +5V
TPE TPD TPK TPL
J2 J2
TB1
HISTD
TPA
TPJ
SIG IN
OUT2
OUT1
3 1
1
1
TPMTPCTPB
TPG
TPH
031-02418-001REV
J1J1To Primary
Stall DetectorDischarge Pressure
(PE -149A)
3
2
1
J1
J2{J3
BLACK
WHITE
RED
1
2
4
3
+5 194
INPUT 171
201
GND 195
RED
BLACK
GREEN
WHITE
BLA
CK
BLA
CK
RE
D
RE
D
J2-3
J2-1
J2-3
J2-1
{ {To P
rimar
yS
tall
Det
ecto
rD
isch
arge
Pre
ssur
e(P
E -1
49A
)
To E
cono
miz
erS
tall
Det
ecto
rD
isch
arge
Pre
ssur
e(P
E -1
49B
)
FIGURE 4 - STALL DETECTOR BOARD DETAILSLD15814
JOHNSON CONTROLS12
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
EMERGENCY STOP
PRIMARY COMPRESSOR PRV CLOSED LIMIT SWITCH
ECONOMIZER COMPRESSOR PRV CLOSED LIMIT SWITCH
PRIMARY COMPRESSOR MOTOR STARTER SAFETY FAULT LOCKOUT RELAY (SEE NOTE 4)
ECONOMIZER COMPRESSOR MOTOR STARTER SAFETY FAULT LOCKOUT RELAYPRIMARY COMPRESSOR MOTOR STARTER RUN INTERLOCK (SEE NOTE 4)
SPARE
PRIMARY COMPRESSOR MAIN OIL PUMP DRIVE FAULTED (OPEN ON FAULT)
ECONOMIZER COMPRESSOR MAIN OIL PUMP DRIVE FAULTED (OPEN ON FAULT)
ECONOMIZER COMPRESSOR THRUST SWITCH
REMOTE HARDWARE START/STOP (RSS)
HARDWARE SAFETY
PRIMARY COMPRESSOR HIGH DISCHARGE PRESSURE CUTOUT
ECONOMIZER COMPRESSOR HIGH DISCHARGE PRESSURE CUTOUT
CHILLED LIQUID LOW FLOW OR DIFFERENTIAL PRESSURE SWITCH (OPTIONAL)
CONDENSER WATER LOW FLOW OR DIFFERENTIAL PRESSURE SWITCH (OPTIONAL)
FIGURE 5 - COMPACT I/O 1769-IAI6 DIGITAL INPUT SLOT 1
LD15816
075-94164-000 SHT 1 Rev.
JOHNSON CONTROLS 13
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
COMPRESSOR OIL HEATER CONTRACTOR
PRIMARY COMPRESSOR MOTOR START/STOP RELAY (SEE NOTE 4)
ECONOMIZER COMPRESSOR MOTOR START/STOP RELAY
PRIMARY COMPRESSOR LIQUID INJECTION SOLENOID VALVE
OIL RETURN SOLENOID VALVE
PRIMARY COMPRESSOR VSOP ENABLE
ECONOMIZER COMPRESSOR VSOP ENABLE
REMOTE READY TO START (RMRS)
FIGURE 6 - COMPACT I/O 1769-OW81 DIGITAL OUTPUT SLOT 2
LD15817
075-94164-000 SHT 1 Rev.
JOHNSON CONTROLS14
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
TCV-100A OPEN PRIMARY COMPRESSOR PRVTCV-100A CLOSE PRIMARY COMPRESSOR PRVTCV-100B OPEN ECONOMIZER COMPRESSOR PRVTCV-100B CLOSE ECONOMIZER COMPRESSOR PRV
PCV-112A OPEN PRIMARY COMPRESSOR VGDPCV-112A CLOSE PRIMARY COMPRESSOR VGDPCV-112B OPEN ECONOMIZER COMPRESSOR VGDPCV-112B CLOSE ECONOMIZER COMPRESSOR VGD
FIGURE 7 - COMPACT I/O 1769-OA8 DIGITAL OUTPUT SLOT 3
LD15818
075-94164-000 SHT 2 Rev.
JOHNSON CONTROLS 15
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
CONDENSER WATER PUMP RUN (R103)
CHILLED LIQUID PUMP RUN (R100)
SAFETY SHUTDOWN (RS)
CYCLING SHUTDOWN(RC)
ALARM (RA)
RESET(RST)
VSD BYPASSENABLE (RBE)
LCSSS TRIGGER BOARD CONTROL POWER
FIGURE 8 - COMPACT I/O 1769-OW81 DIGITAL OUTPUT SLOT 4
LD15819a
075-94164-000 SHT 2 Rev. C
JOHNSON CONTROLS16
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
PE-111EVAPORATORREFRIGERANTPRESSURE6-74 PSIG
PE-113CONDENSERREFRIGERANTPRESSURE0-300 PSIG
PE-116ECONOMIZERREFRIGERANTPRESSURE0-300 PSIG
PE-140OIL SUMPPRESSURE0-300 PSIG
PE-141APRIMARY COMPRESSOR OILPUMP PRESSURE0-300 PSIG
PE-141BECONOMIZER COMPRESSOR OILPUMP PRESSURE0-300 PSIG
(DO NOT CONNECT EXCEPT FOR EM STARTER) IT-160A PRIMARY MOTOR CURRENT 4-20mA 0-125% FLA
PE-149APRIMARY COMPRESSOR DISCHARGEPRESSURE0-300 PSIG
FIGURE 9 - COMPACT I/O 1769-IF8 ANALOG INPUT SLOT 5
LD15820
075-94164-000 SHT 2 Rev.
JOHNSON CONTROLS 17
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
XE-149APRIMARY COMPRESSOR VGD STALL BOARD SIGNAL/NOISE0-5V
ZE-149APRIMARY COMPRESSOR VGD POSITION0-100%
PE-149BECONOMIZER COMPRESSOR DISCHARGE PRESSURE0-300 PSIG
XE-149BECONOMIZER COMPRESSOR VGD STALL BOARD SIGNAL/NOISE0-5V
ZE-149BECONOMIZER COMPRESSOR VGDPOSITION0-100%
LE-114SUBCOOLER REFRIGERANTLEVEL SENSOR0-100%
LE-116ECONOMIZERLEVEL SENSOR0-100%
ZE-142APRIMARY COMPRESSORAXIAL THRUST POSITION-0.865 TO 112.428 MILS0-5VDC
FIGURE 10 - COMPACT I/O 1769-IF8 ANALOG INPUT SLOT 6
LD15826
075-94164-000 SHT 2 Rev.
JOHNSON CONTROLS18
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
+5VDC REFERENCE
ZE-100APRIMARY COMPRESSOR PRV0-100%
ZE-100BECONOMIZER COMPRESSOR PRV0-100%
RST-100LEAVING CHILLED LIQUID REMOTE SET POINT
RST-160DEMAND LIMITREMOTE
FSLL-100EVAPORATOR CHILLEDLIQUID FLOW
FSLL-103CONDENSER WATER FLOW
SPARE
FIGURE 11 - COMPACT I/O 1769-IF8 ANALOG INPUT SLOT 7
LD15827
075-94164-000 SHT 3 Rev.
JOHNSON CONTROLS 19
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
TE-100LEAVING CHILLEDLIQUID TEMPERATURE
TE-101ENTERING CHILLEDLIQUID TEMPERATURE
TE-102ENTERING CONDENSER WATER TEMPERATURE
TE-103LEAVING CONDENSER WATER TEMPERATURE
TE-111EVAPORATOR REFRIGERANT LIQUID TEMPERATURE
TE-114SUBCOOLED REFRIGERANT LIQUID TEMPERATURE
FIGURE 12 - COMPACT I/O 1769-IR6 RTD INPUT SLOT 8
LD15828
075-94164-000 SHT 3 Rev.
JOHNSON CONTROLS20
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
TE-140OIL SUMPTEMPERATURE
TE-112PRIMARY COMPRESSORDISCHARGETEMPERATURE
TE-113ECONOMIZER COMPRESSORDISCHARGETEMPERATURE
SPARE
SPARE
SPARE
FIGURE 13 - COMPACT I/O 1769-IR6 RTD INPUT SLOT 9
LD15829
075-94164-000 SHT 3 Rev.
JOHNSON CONTROLS 21
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
PRIMARY COMPRESSOR OIL PUMP SPEED
ECONOMIZER COMPRESSOR OIL PUMP SPEED
NOTE:FOR SLOT 10 SET EXTERNAL POWER SWITCH TO DOWN POSITION.
FIGURE 14 - COMPACT I/O 1769-OF2 ANALOG OUTPUT SLOT 10
LD15830
075-94164-000 SHT 3 Rev.
JOHNSON CONTROLS22
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
SUBCOOLER LEVEL VALVE ACTUATOR 0-10VDC
ECONOMIZER LEVEL VALVE ACTUATOR0-10VDC
HOT GAS VALVE ACTUATOR0-10VDC
+10VDCVSD POWER SUPPLY
FIGURE 15 - COMPACT I/O 1769-OF4VI ANALOG OUTPUT SLOT 11
LD15831
075-94164-000 SHT 3 Rev.
JOHNSON CONTROLS 23
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
FIGURE 16 - OIL PUMP
Oil Sump Temperature Sensor
Oil Sump Pressure Transducer
To Control Panel
To Control Panel
(VSOP)
To Control Panel
(Hole D)
To Control Panel
(Hole A and H)
To VS Oil Pump Panel
LD15774
JOHNSON CONTROLS24
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
FIGURE 17 - SUBCOOLER / OIL SUMP
FIGURE 18 - LIQUID COOLED SOLID STATE STARTER
Subcooler Level Valve Actuator
Subcooled Refrigerant Liquid Temperature Sensor
Oil Sump Temperature Sensor
Oil Sump Pressure Transducer
LD15776
LD15775
JOHNSON CONTROLS 25
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
FIGURE 19 - ACTUATOR WIRING
FIGURE 20 - CONNECTOR DETAILS
WHITE
BLACK
RED
LD15724a
LD15777
JOHNSON CONTROLS26
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
FIGURE 21 - COMPONENT CONNECTION DETAILS
Actuator Details
Chilled and CondenserWater Flow Switches
(FSLL-100 and FSLL-103)
Liquid Level SensorStall Detector Pressure Transducer
LD15725
JOHNSON CONTROLS 27
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1LEGEND
CB CIRCUIT BREAKERFLA FULL LOAD AMPSFU FUSEHTRIA/B 3 PHASE THERMOSTATICALLY
CONTROLLED 3000W OIL HEATERLCSSS LIQUID COOLED SOLID STATE STARTERMIA/B OIL HEATER CONTACTORMOV METAL OXIDE VARISTORMVVSD MEDIUM VOLTAGE VARIABLE SPEED
DRIVE (REMOTE MOUNTED)MVSSS MEDIUM VOLTAGE SOLID STATE
STARTER (REMOTE MOUNTED)OL MOTOR STARTER OVERLOADPRV PRE-ROTATION VANE MOTORPS POWER SUPPLYR RELAYRES RESISTORSSR SOLID STATE RELAYSUPR TRANSIENT SUPPRESSORTB TERMINAL BASETS TEMPERATURE SWITCHUMMVSSS UNIT MOUNTED MEDIUM VOLTAGE
SOLID STATE STARTER
VSDA/B VARIABLE SPEED OIL PUMP DRIVE FAULT CONTACT
ZS LIMIT SWITCHFIELD WIRINGFACTORY WIRINGCIRCUIT BOARD OR ENCLOSURE BOUNDARYFACTORY SYSTEM WIRING
SHIELDED CABLE
METAL OXIDE VARISTOR
TERMINAL CONNECTION POINT ON COMPONENTTERMINAL CONNECTION POINT IN MAIN CONTROL POINTTERMINAL CONNECTION POINT IN VS OIL PUMP PANELTERMINAL CONNECTION POINT IN PRIMARY COMPR. MOTOR STARTERTERMINAL CONNECTION POINT IN LCSSSINCOMING/OUTCOMING WIRE THRU PANEL MOUNT RECEPTACLE
JOHNSON CONTROLS28
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
FIGURE 22 - ELEMENTARY DIAGRAM
ELEMENTARY DIAGRAM
LD15762
075-94164-000 SHT 1 Rev. C
JOHNSON CONTROLS 29
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
PRIMARY COMPRESSOR
COMPRESSOR ACTUATORS
ECONOMIZER COMPRESSOR
FIGURE 23 - COMPRESSOR ACTUATORS / STALL DETECTOR BOARDSLD15770
JOHNSON CONTROLS30
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
VSOP PANEL WIRING
FIGURE 24 - VARIABLE SPEED OIL PUMP PANEL WIRINGLD15771
JOHNSON CONTROLS 31
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
THIS PAGE INTENTIONALLY LEFT BLANK
JOHNSON CONTROLS32
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
WIRING DIAGRAM
FIGURE 25 - WIRING DIAGRAMLD15772
JOHNSON CONTROLS 33
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1WIRING DIAGRAM (CONT'D)
FIGURE 25 - WIRING DIAGRAM (CONT'D)LD15773
075-94164-000 SHT 5 Rev. C
JOHNSON CONTROLS34
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
FIGURE 26 - 120VAC AND LOW VOLTAGE CONNECTION DIAGRAM
120VAC AND LOW VOLTAGE CONNECTION DIAGRAM
LD15778
BOTTOM OF ENCLOSURE
JOHNSON CONTROLS 35
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
INSIDE OF PANEL DOORBOTTOM OF ENCLOSURE
120VAC AND LOW VOLTAGE CONNECTION DIAGRAM (CONT'D)
FIGURE 26 - 120VAC AND LOW VOLTAGE CONNECTION DIAGRAM (CONT'D)LD15779
075-94164-000 SHT 6 Rev.
JOHNSON CONTROLS36
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
INSIDE BOTTEM OF CONTROL PANEL
ECONOMIZER COMPRESSOR
CONNECTION DIAGRAM
FIGURE 27 - CONNECTION DIAGRAMLD15780
JOHNSON CONTROLS 37
SECTION 1 - UNIT WIRINGFORM 160.77-PW2 ISSUE DATE: 9/23/2011
1
INSIDE BOTTEM OF CONTROL PANEL
ECONOMIZER COMPRESSOR
CONNECTION DIAGRAM (CONT'D)
FIGURE 27 - CONNECTION DIAGRAM (CONT'D)LD15781
075-94164-000 SHT 7 Rev.
JOHNSON CONTROLS38
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 1 - UNIT WIRING
VARIABLE SPEED OIL PUMP PANEL
FIGURE 28 - VARIABLE SPEED OIL PUMP PANEL
LD15782
075-94164-000 SHT 8 Rev.
VS OIL PUMP PANEL POWER SUPPLY
VOLTS-PH-HZPANEL
MAXIMUM FLA
MINIMUM CIRCUIT
AMPACITY
MAXIMUM DUAL
ELEMENT FUSE SIZE
200-3-60 22.24 24 30208-3-60 21.86 24 30220-3-60 20.24 22 25230-3-60 19.90 22 25240-3-60 19.53 22 25380-3-60 11.86 13 15416-3-60 11.41 13 15440-3-60 10.15 11 12460-3-60 9.95 11 12480-3-60 9.77 11 12550-3-60 8.03 9 10575-3-60 7.88 9 10600-3-60 7.73 9 10
346-3-50 13.20 15 20380-3-50 11.86 13 15400-3-50 11.60 13 15415-3-50 11.42 13 15
JOHNSON CONTROLS 39
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
2
SECTION 2 - FIELD CONTROL MODIFICATIONS
1. These FIGURES show recommended field con-trol wiring modifications (by others) to the stan-dard Control Center Wiring Diagram.
2. If more than one of these modifications is to be utilized with a particular unit, additional consid-eration must be given to the application to insure proper functioning of the control system. Consult your YORK/Johnson Controls representative.
3. The additional controls and wiring for these modi-fications are to be furnished and installed in the field by others (see Warnings on page 2).
4. The controls specified are recommended for use, but other controls of equal specifications are ac-ceptable.
5. All wiring shall be in accordance with the Nation-al Electrical Code, and applicable State and Local Codes.
6. Each 115VAC field connected inductive load, i.e. relay coil, motor starter coil, etc., shall have a transient suppressor wired (by others) in parallel with its coil, physically located at the coil. Spare transient suppressors are furnished in a bag in the Control Center.
7. The Control Center is factory furnished for Manu-al Restart After Power Failure as a standard func-tion.
8. Two (2) unit controls schemes are suitable for 8° – 12°F water range. Constant chilled water flow is assumed at all loads. For other requirements con-tact your YORK/Johnson Controls representative.
9. Sequence control kits (see Figure 36 on Page 42) assume a constant chilled water flow and a constant leaving chilled water temperature to sense the cooling load. Sequence control kits are not designed for variable chilled water flow or with reset of the leaving chilled water tempera-ture – see Figures 29 to 32.
10. Maximum allowable current draw between cir-cuits 24 and 2 for field installed devices is 2 amp holding and 10 amps inrush – see Control Center Wiring Diagram in this manual.
11. For required field wiring connections of the chilled water pump contacts (terminals B3 and 2 on Control Center field wiring terminal block IFM4) and chilled water flow switch (terminals 1 and 65 on Control Center field wiring terminal)(see Wiring Diagram Field Connections Form 160.77-PW2).
12. The Chilled Water Flow Switch is a safety con-trol. It must be connected to prevent operation of the chiller whenever chilled water flow is stopped. The use of the chilled water flow switch for pur-poses other than protection of the chiller may be accomplished in several ways. Two flow switches, a flow switch and a relay or separate contacts on the same flow switch.
13. Do not apply voltage on field wiring terminal blocks IFM2 and IFM4 in YORK Control Center, as 115VAC source is fed from terminals 1 and 2 .
JOHNSON CONTROLS40
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 2 - FIELD CONTROL MODIFICATIONS
REMOTE MODE READY TO START CONTACTS
When closed, these contacts signify the following:
1. All chiller safety cutout controls are in the normal position, so they will allow the unit to start.
2. All chiller cycling cutout controls are in the nor-mal position, so they will allow the unit to start.
3. The Control Center chiller start Green pushbutton on the house screen Graphics display page illu-minated.
4. Any applicable anti-recycle timer has timed out. A closure of the Remote Mode Ready to Start Con-tacts then signifies that the unit shall start when the Energy Management System maintains the Remote Stop Contact open and momentarily clos-es the Remote Start Con tact. When the Remote Mode Ready to Start Contacts close, the Control Center will display READY TO START message.
IFM2 1 B9
1 90
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTIVE @ 120VAC
FIGURE 29 - REMOTE READY TO START CONTACTSLD15832
CYCLING SHUTDOWN CONTACTS
When closed, these contacts signify the unit is not per-mitted to start due to a CYCLING shutdown condition. The unit will automatically restart after the cycling condition is no longer present. YKEP Unit Operation and Maintenance (Form 160.77-O1) provides a list and explanation of all Cycling Shutdowns. While these contacts are closed, the Control Center will display STOPPED – CYCLED OFF on the System Status Bar and the cause of the shutdown on the System Details bar of the display. Cycling Shutdown contacts function in all operating modes.
FIGURE 30 - CYCLING SHUTDOWN CONTACTS
IFM4 1 B5
1 134
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTIVE @ 120VAC
LD15833
SAFETY SHUTDOWN CONTACTS
When closed, these contacts signify the unit is not permit-ted to start due to a SAFETY shutdown condition. Safety shutdowns require a manual reset procedure be performed before the unit can be restarted. YKEP Unit Operation and Maintenance (Form 160.77-O1) provides a list and explanation of all Safety Shutdowns. While these con-tacts are closed, the Control Center will display SYSTEM TRIPPED on the System Status Bar and the cause of the shutdown on the System Details Bar of the display. These contacts will remain closed until the safety condition no longer exists and a manual reset is performed by press-ing the clear faults key on the control panel. The unit can then be restarted. Safety Shutdown contacts function in all operating modes.
FIGURE 31 - SAFETY SHUTDOWN CONTACTS
IFM4 1 B4
1 132
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTIVE @ 120VAC
LD15834
RUN CONTACTS
When closed, these contacts signify that the unit is op-erating. The Control Center will display a System Run Message.
FIGURE 32 - RUN CONTACTS
IFM4 1 B2
1 128
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS RESISTIVE @ 120VAC
LD15835
JOHNSON CONTROLS 41
SECTION 2 - FIELD CONTROL MODIFICATIONSFORM 160.77-PW2 ISSUE DATE: 9/23/2011
2
ANTICIPATORY/ALARM CONTACTS
These contacts will close whenever one or more of the following WARNING conditions occurs. They will re-main closed as long as the condition is in effect. On most warnings, the contacts automatically open when the condition is no longer present. On those warnings marked with an asterisk, the contacts will open only after the condition is no longer present and the WARN-ING RESET key is pressed in Operator (or higher) ac-cess level.
Real time clock failure, Condenser or Evaporator Transducer Error*, Setpoint Override*, Condenser-High Pressure Limit, Evaporator-Low Pressure Limit.
FIGURE 33 - ANTICIPATORY/ALARM CONTACTS
IFM4 1 B6
1 136
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTION @ 120VAC
LD15836
REMOTE START AND STOP CONTACTS FROM ENERGY MANAGEMENT SYSTEM
When the Control Center is in the remote operating mode and the compressor switch is in the “run” (l) po-sition, with the Remote Stop Contacts open, and the Remote Mode Ready to Start Contacts closed (see Fig-ure 29 on Page 40), the unit will start via a closure of the Remote Start Contacts. A subsequent opening of the Energy Management System Remote Start Con-tacts causes the chiller to shut down. The Control Cen-ter will display REMOTE STOP because the Energy Management System Remote Stop Contact has com-manded the unit to shutdown.
Even when the chiller is applied with Re‑mote Start‑Stop (when the Control Center is in the “Remote Operating Mode"), an EMERGENCY STOP by an operator or others can STOP the compressor from the Control Center and prevent the chiller from restarting. However, the operator cannot locally start the compressor using “start” button, when the control center is in the “remote” operating mode.
FIGURE 34 - REMOTE START AND STOP CON-TACTS FROM ENERGY MANAGEMENT SYSTEM CONTACTS
2 62 1FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
STARTCONTACT RATING 5 mA @ 115VAC
LD15837
CHILLED WATER PUMP STARTER (IFM4-B3 AND 1)When the chiller is started, the Contacts close immedi-ately upon entering “Startup”. Normally, they open co-incident with the completion of “System Coastdown” with the following exceptions:
If a LEAVING CHILLED LIQUID - LOW TEMPER-ATURE cycling shutdown occurs, they do not open at the completion of “System Coastdown”. They remain closed for the duration of the shutdown or until Stop is selected at the keypad, whereupon they open.
If LEAVING CHILLED LIQUID FLOW SWITCH OPEN cycling shutdown occurs, they remain closed until the chiller is giveen a stop command or another fault oc-curs.
FIGURE 35 - CHILLED WATER PUMP STARTER
IFM4 1 B3
1 130
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTIVE @ 120VAC
LD15838
JOHNSON CONTROLS42
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 2 - FIELD CONTROL MODIFICATIONS
CONDENSER MOTOR PUMP STARTER (IFM4-B2 AND 1)
Contacts close coincident with beginning of “Startup”. They open after postlube sequence.
FIGURE 36 - CONDENSER MOTOR PUMP STARTER
IFM4 1 B2
1 128
TO ENERGY MANAGEMENT SYSTEM FROM CHILLER
FIELD WIRING TERMINAL BLOCK IN CONTROL CENTER
POWERED OUTPUT (IN CONTROL CENTER) RATED 2 AMPS INDUCTIVE @ 120VAC
LD15839
CONDENSER FLOW SENSORS
The Effector-type Flow Sensor interfaces with the Analog Input and Paddle-type Flow Sensor interfaces with the digital input module.
For the program to read the appropriate inputs for the flow sensor status, the actual flow sensor type used must be entered at the keypad FACTORY SETUP Screen using Service Access Level.
When flow is sensed, the flow sensor contacts are closed. Opening of the flow sensor contacts (no flow) for 30 continuous seconds causes a cycling shutdown displaying “LOW CONDENSER WATER FLOW”. The flow sensor status is bypassed for the first 30 sec-onds of “System Run”.
If Paddle-type (Digital) is selected and no condenser flow sensor is used, a jumper must be installed be-tween terminals 252 and 194 .
Condenser Effector Type Flow SensorWhen the Effector-type Flow Switch is used, the flow switch uses the cooling effect of liquid to sense flow.
When the flow of liquid is sensed, the solid state relay output is turned on conducting current through the mi-croboard load resistor to the +5VDC applying greater than +4VDC to the input Slot 7, Channel 6.
When no flow of liquid is sensed, the solid state re-
lay output is turned off, this results in less than 1VDC to the microboard input and the Control Center will display the following message: LOW CONDENSER WATER FLOW.
FIGURE 37 - CONDENSER FLOW SWITCHES
I/O BOARD PADDLE-TYPE FLOW SENSOR
EFFECTOR-TYPE FLOW SENSORSLOT 7
CHILLED LIQUID
CONDENSER
LD15840
Condenser Paddle Type Flow SensorIf desired, a Condenser Water Flow Interlock can be applied. Flow Switch – McDonnel type FS8W, max. 150 psi (YORK Part No. 024-15793) available at ad-ditional cost. If Condenser Water Flow Switch is not used, a jumper must be installed between terminals 1 and 68 .
When condenser water is flowing, the flow switch con-tact will close. Opening of the Condenser Water Flow Switch Contacts for 2 continuous seconds will cause unit shutdown. The flow switch status is checked 30 seconds into “System Run” and continuously thereaf-ter. The Control Center will display the following mes-sage: LOW CONDENSER WATER FLOW.
EVAPORATOR FLOW SENSORS
The Effector-type Flow Sensor interfaces with the Analog Input and Paddle-type Flow Sensor interfaces with the digital input module.
For the program to read the appropriate inputs for the flow sensor status, the actual flow sensor type used must be entered at the keypad FACTORY SETUP Screen using Service the Access Level.
JOHNSON CONTROLS 43
SECTION 2 - FIELD CONTROL MODIFICATIONSFORM 160.77-PW2 ISSUE DATE: 9/23/2011
2
TWO UNIT SEQUENCE CONTROL
Provides that cycling thermostat RWT will automati-cally cycle either #1 or #2 unit. Timer 3TR is an addi-tional feature which prevents simultaneous starting of lead and lag unit following a power failure and elimi-nates nuisance starting of lag unit due to periodic fluc-tuations in temperature. For two unit sequence control kit, order YORK Accessory Kit No. 466-61597T for controls as specified with NEMA 1 enclosure.
RWT has 20°F to 80°F range with adjustable differen-tial of 3-1/2 to 14°F; 6 ft. of capillary with 3/8" x 5" bulb and 1/2" NPT brass well (maximum liquid DWP 300 psig). The thermostat is drawn to indicate its oper-ation closes on rise. A 1/2" pipe coupling in the return chilled water line from the building must be furnished (by others) for RWT control well.
MULTIPLE UNITS (TWO) - SERIES OPERATION
The supply chilled water temperature to the building is normally determined by the “Chilled Liquid Temp.” setpoint for Unit #2. When lead selector position of se-quence control kit (Refer to Figure 39 on Page 44) is Unit #1, the supply chilled water temperature to the building will be the temperature control setpoint on Unit #1 Control Center. If lower temperature is de-sired, reprogram the “Chilled Liquid Temp.” setpoint for Unit #1.
When flow is sensed, the flow sensor contacts are closed. Opening of the flow sensor contacts (no flow) for 2 continuous seconds causes a shutdown displaying “LOW CHILLED WATER FLOW”. The flow sensor status is bypassed for the first 25 seconds of “System Prelube”.
FIGURE 38 - EVAPORATOR FLOW SENSORS
I/O BOARD PADDLE-TYPE FLOW SENSOR
EFFECTOR-TYPE FLOW SENSORSLOT 7
CHILLED LIQUID
CONDENSER
LD15840
Evaporator Effector Type Flow SensorWhen the Effector-type Flow Switch is used, the flow switch uses the cooling effect of liquid to sense flow.
When the flow of liquid is sensed, the relay output is turned on conducting current through the microboard load resistor to the +5VDC applying greater than +4VDC to the input Slot 7, Channel 5.
When no flow of liquid is sensed, the relay output is turned off, this results in less than 1VDC to the input Slot 7, Channel 5.
Evaporator Paddle Type Flow SensorWhen Evaporator Water is flowing, the flow switch con tact will close. If the flow switch opens for 2 sec-onds, the unit shuts down.
If desired, a Condenser Water Flow Interlock can be applied. Flow Switch – McDonnel type FS8W, max. 150 psi (YORK Part No. 024-15793) available at ad-ditional cost. If Condenser Water Flow Switch is not used, a jumper must be installed between terminals 1 and 65 .
JOHNSON CONTROLS44
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 2 - FIELD CONTROL MODIFICATIONS
FIGURE 39 - TWO UNIT SEQUENCE CONTROLLD15842
FIELD CONNECTION DIAGRAM
ELEMENTARY DIAGRAM
TERMINAL BOARD IN SEQUENCING CONTROL BOX
2 131 130 13-1 14-113-2 14-2GRD. SCREWS
RWT
SEE NOTE AASEE NOTE CC
SELECTOR SWITCH NOTE FF
FIELD WIRING
LEAD UNIT
1
13-1
14-1
13-2
14-2
2
133
UNIT #1 UNIT #2
FIELD WIRING TERMINAL BLOCKS IN CONTROL CENTER
2 2 62 162 1
130RWT
3TR
131 3TR
NOTE EE
NOTE 6
SUPR.
2
NOTES:AA. RWT - RETURN WATER THERMOSTAT BY YORK.CC. ALL REMOTE WIRING (BY OTHERS) TO BE #14 AWG COPPER CLASS 1 N.E.C. CONTROL WIRE.DD. ALL CONTACTS HAVE A MAXIMUM RATING OF 125 VA @ 125VAC 50/60 HZ.EE. 3TR - TIME DELAY RELAY, 100 SEC., “ON” DELAY.FF. 4 POLE, DOUBLE THROW SNAP SWITCH (TOGGLE)
TWO UNIT SEQUENCE CONTROL - PARALLEL OR SERIES WATER FLOW - LEAD SELECTOR AND CYCLING THERMOSTAT (NOTES 2, 6, 8, 9, 10 AND 11)
FIGURE 40 - MULTIPLE UNITS (TWO) - SERIES OPERATIONLD15842a
RWT LOCATION (IF USED)
RWT
COOLER
UNIT #1
COOLER
UNIT #2
TEMPERATURE CONTROL FUNCTION IN CONTROL CENTER
CHILLED WATER PIPING SCHEMATIC
T.S. = TEMPERATURE SENSING UNITS
T.S. T.S.
JOHNSON CONTROLS 45
SECTION 2 - FIELD CONTROL MODIFICATIONSFORM 160.77-PW2 ISSUE DATE: 9/23/2011
2
MULTIPLE UNITS (TWO) – PARALLEL OPERATION – INDIVIDUAL UNIT PUMPS
This piping arrangement is the same as Figure 36 on Page 42, except that the chilled water pumps associ-ated with each evaporator are cycled ON and OFF with the unit. This results in reduced chilled water flow rates whenever a single unit can handle the cooling load. Be-cause no chilled water flows through the inoperative unit, the mixed water temperature peculiar to using a single pump is avoided. When one unit is cut-out by the sequence control (refer to Figure 39 on Page 44) the temperature of the supply chilled water does not change.
FIGURE 41 - MULTIPLE UNITS (TWO) PARALLEL OPERATION - INDIVIDUAL UNIT PUMPS
RWT LOCATION (IF USED)
TEMPERATURE CONTROL FUNCTION IN CHILLER CONTROL CENTER
COOLER
T.S.
T.S.
SUPPLYCHILLED
TEMPERATURE CONTROL FUNCTION IN CHILLER CONTROL CENTER
UNIT # 1
COOLERUNIT # 2
CHILLED WATER PIPING SCHEMATIC
MULTIPLE UNITS - PARALLEL OPERATION: IN THIS ARRANGEMENTS, THE INDIVIDUAL CHILLED WATER PUMP IS STOPPED WHEN THE ONE UNIT IS SHUT DOWN AT APPROXIMATELY 40% SYSTEM LOAD. LEAVING CHILLED WATER TEMPERATURE IS CONSTANT (± 1/2°F) AT ALL LOADS. (NOTES 8 and 11)
WATER TO SYSTEM
T.S. = TEMPERATURE SENSING UNITS
LD15845
MULTIPLE UNITS (TWO) – PARALLEL OPERATION – SINGLE CHILLED WATER PUMP
For this piping arrangement, each chiller’s water sen-sor is located in its own leaving water nozzle. This produces a constant “mixed” chilled water tempera-ture when both units are operating. When either unit is cycled off by the sequence control (see Figure 39 on Page 44), mixed chilled water temperature will rise as a result of uncooled return water flowing through the inoperative unit. For individual unit chilled water pump piping, refer to Figure 42 on Page 45.
FIGURE 42 - MULTIPLE UNITS (TWO) PARALLEL OPERATION - SINGLE CHILLED WATER PUMP
RWT LOCATION (IF USED)
TEMPERATURE CONTROL FUNCTION IN CHILLER CONTROL CENTER
COOLER
T.S.
T.S.
SUPPLY CHILLEDWATER TO SYSTEM
TEMPERATURE CONTROL FUNCTION IN CHILLER CONTROL CENTER
UNIT # 1
COOLERUNIT # 2
CHILLED WATER PIPING SCHEMATICMULTIPLE UNITS - PARALLEL OPERATION: IN THIS ARRANGEMENTS, WHEN ONE UNIT IS SHUT DOWN AT APPROXIMATELY 40% LOAD, THE CHILLED WATER TEMPERATURE SUPPLY TO THE SYSTEM RISES TO THE MIXED TEMPERATURE OF THE CHILLED WATER LEAVING BOTH UNITS, FOR ALL LOADS DOWN TO MINIMUM CAPACITY. LEAVING CHILLED WATER TEMPERATURE IS CONSTANT (± 1/2°F) AS LONG AS BOTH UNITS ARE IN OPERATION. (NOTES 8 and 11)
T.S. = TEMPERATURE SENSING UNITS
LD15845a
REMOTE LEAVING CHILLED LIQUID SETPOINT
Remote Leaving Chilled Liquid Temperature Setpoint Reset can be accomplished by supplying (by others) 4-20mA or Control Center. The Leaving Chilled Liq-uid Temperature Setpoint is programmable over the range of 38°F to 70°F (water applications), 36°F to 70°F (water applications with Smart Freeze Protection enabled) or 10°F to 70°F (brine applications). The Re-mote Input Signal changes the setpoint by creating an offset above the locally programmed Leaving Chilled Liquid Temperature Base Setpoint value. The setpoint can be remotely changed over the range of 10° or 20ºF (as per the locally programmed Remote Reset Tem-perature Range setpoint) above the Local Leaving Chilled Liquid Temperature Setpoint. For example, if the Local Setpoint is 40°F and the Remote Reset Tem-perature Range setpoint is programmed for 10°F, the Leaving Chilled Liquid Temperature setpoint can be remotely reset over the range of 40°F to 50°F.
{+0°F to +10°F = 4-20mA setpoint above programmable level setpoint
Channel 3 Slot 7
246
245
247
FIGURE 43 - REMOTE HARDWIRED ANALOG TEMPERATURE SETPOINT
LD15844
JOHNSON CONTROLS46
FORM 160.77-PW2 ISSUE DATE: 9/23/2011SECTION 2 - FIELD CONTROL MODIFICATIONS
DEMAND LIMIT REMOTE
Remote Demand Limit can be accomplished by sup-plying (by others) 4-20mA or Control Center. The De-mand Limit is programmable over the range of 40% - 100%. The Remote Input Signal changes the setpoint when set for remote setpoint on the SETPOINTS SCREEN refer to YKEP Unit Operation and Mainte-nance (Form 160.77-O1). The setpoint can be remote-ly changed over the range of 40% - 100%.
{To EMS 4-20 mA = 40% to 100% load
Channel 4 Slot 7
249
251
250
FIGURE 44 - DEMAND LIMIT HARDWIRED REMOTELD15843
EXTERNAL SIGNAL FOR REFRIGERATION UNIT FAILURE
When the Safety Shutdown Contacts (see Safety Shut-down Contacts on Page 40) are not connected to an Energy Management System they may be employed to energize a local or remote safety alarm (by others). When the normally open Safety Shutdown Contacts close, the alarm will indicate shutdown of the unit. The cause of shutdown will be one or more of the follow-ing safety controls: low oil pressure; high oil pressure; high condenser pressure; low evaporator pressure; high oil temperature; high discharge temperature; auxiliary safety; power failure.
If the unit was shut down because of Cycling Shutdown Contacts (see Figure 20) the alarm will not be energized, but the unit will have been shut down. A clo‑sure of the safety alarm contacts means that an operator must manually reset and restart the unit.
JOHNSON CONTROLS 47
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
3
SECTION 3 - ENERGY MANAGEMENT SYSTEMS
YKEP chiller design allows for ease of interfacing with Energy Management Systems (EMS). The Control Center includes unit status contacts, provisions for re-mote control inputs and provisions for remote setpoint reset of leaving chilled liquid temperature and current limit for EMS interfacing (see Note 7).
Five sets of unit status outputs are factory furnished through a field wiring terminal board in the Control Center. Each set of contacts are 170VAC power out-puts, rated at 2 amperes resistive at 120VAC. Chiller status contacts are provided for unit:
• Remote Mode Ready to Start – See Figure 29 on Page 40.
• Cycling Shutdown – See Figure 30 on Page 40.
• Safety Shutdown – See Figure 31 on Page 40.
• Run (System Operating) – See Figure 32 on Page 40.
• Anticipatory/Alarm – See Figure 33 on Page 41.
One input is available to the EMS, allowing for remote control of unit operation. Input device contact rating shall be 5 milliamperes at 115VAC. Field wiring termi-nal 62 in the Control Center permits connection for the following operation Remote Start/Stop Contacts – See Figure 24.
Chiller cycling by the Energy Management System should be minimized. It is possible to limit the com-pressor motor amp draw indirectly or directly by the following methods:
1. Application of Sequence Control Kit, so only one unit is running, when a single unit can carry the cooling load – see Figure 26 on Page 34.
2. Reduce the compressor-motor kW input (and thus amps), by raising the leaving chilled liquid tempera ture through remote temperature control setpoint in the “remote” operating mode. When remote tem perature reset is accomplished by sup-plying a 4-20 mA signal, refer to Figure 43 on Page 45. Through use of the remote tempera-ture control analog input on Slot 7, Channel 3, the leaving chilled liquid temperature may be reset via a 4 to 20mA D.C. current signal.
3. Current limiting of demand during pulldown may be accomplished by using the standard PULL-DOWN DEMAND LIMIT function provided in the Control Center. The “Pulldown Demand Limit” key can be programmed to limit compres-sor motor current from 40 to 100 percent of full load amperes, for 1 to 255 minutes following each compressor start. For more details refer to YKEP Unit Operation and Maintenance (Form 160.77-O1).
4. Controlling the maximum allowable compressor motor amps from 40 to 100% through remote cur-rent limit setpoint. Refer to Figure 44 on Page 46 when the remote current limit is accom-plished by supplying a 4-20 mA the “remote” op-erating mode. Remote current limit setpoint via a 4 to 20mA D.C. current signal.
5. The Johnson Controls METASYS™ System may be interfaced with the chiller Control Center to provide unified chiller plant system control. The METASYS™ System directly communicates with the Control Center via the E-Link Gateway card which may be installed in the Control Cen-ter. All temperatures, pressures, safety alarms and cycling information known to the Control Center are then available to the METASYS™ System for integrated chiller plant control, data logging, and local and remote operator displays. The META-SYS™ E-Link Gateway card also allows the Mol-bus RTU to start, stop, and reset the chiller’s leav-ing chilled water and current limit setpoints.
Modbus RTU via RS-485 is available to commu-nicate directly to the chiller Control Center with-out an E-Link.
JOHNSON CONTROLS48
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
NOTES
JOHNSON CONTROLS 49
FORM 160.77-PW2 ISSUE DATE: 9/23/2011
The following factors can be used to convert from English to the most common SI Metric values.
TEMPERATURE
To convert degrees Fahrenheit (°F) to degrees Celsius (°C), subtract 32° and multiply by 5/9 or 0.5556.
Example: (45.0°F - 32°) x 0.5556 = 27.2°C
To convert a temperature range (i.e., a range of 10°F) from Fahrenheit to Celsius, multiply by 5/9 or 0.5556.
Example: 10.0°F range x 0.5556 = 5.6 °C range
TABLE 1 - SI METRIC CONVERSION
MEASUREMENT MULTIPLY ENGLISH UNIT BY FACTOR TO OBTAIN METRIC UNIT
Capacity Tons Refrigerant Effect (ton) 3.516 Kilowatts (kW)
Power Horsepower 0.7457 Kilowatts (kW)
Flow Rate Gallons / Minute (gpm) 0.0631 Liters / Second (l/s)
LengthFeet (ft) 304.8 Meters (m)
Inches (in) 25.4 Millimeters (mm)
Weight Pounds (lbs) 0.4538 Kilograms (kg)
Velocity Feet / Second (fps) 0.3048 Meters / Second (m/s)
Pressure DropFeet of Water (ft) 2.989 Kilopascals (kPa)
Pounds / Square Inch (psi) 6.895 Kilopascals (kPa)
P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USACopyright © by Johnson Controls 2011 ALL RIGHTS RESERVEDForm 160.77-PW2 (911)Issue Date: September 23, 2011 Supersedes: 160.77-PW2 (311)
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